Process for insert molding wet-shaving razor unit and unit made therefrom

Abstract

The present invention is a wet-shaving unit and a process for making same by injection molding. Additionally, the present invention provides an apparatus for molding the wet-shaving razor unit. The present invention is adaptable for addition to conventional razor blade manufacturing methods and existing manufacturing apparatus and facilities. Moreover, the present process results in a product which significantly reduces or eliminates entirely undesirable blade distortion and vibration.

What is claimed is: 
     
       1. An apparatus for insert molding a wet-shaving razor unit comprising: a composite seat blade support having male mold members in fluid communication with a cap-forming male mold portion, said seat blade support providing a seat cavity portion for forming a flexible seat portion;   said cap-forming male mold portion which provides a cap cavity portion for forming a flexible cap, said cap cavity portion in fluid communication with said seat cavity portion to form a mold region, said cap-forming male mold portion being sealingly engageable with said seat blade support;   at least one alignment pin extending between said seat cavity portion and said cap cavity portion for receipt of a blade thereon and securement during molding; and   at least one injection port in fluid communication with one of said seat cavity portion and said cap cavity portion for injecting thermoplastic material.   
     
     
       2. The apparatus according to claim 1 further comprising a spacer bar positioned adjacent to a seat blade which support a cap blade and positions said cap blade in spaced relationship to said seat blade. 
     
     
       3. The apparatus according to claim 2 wherein said spacer bar includes finger elements between which thermoplastic support fingers are formed during molding. 
     
     
       4. The apparatus according to claim 1 further comprising mechanical pusher elements extending upward within said seat blade support into said mold region and which form a pair of opposing handle-receiving cavities on said unit and which eject said unit from said apparatus for removal therefrom. 
     
     
       5. The apparatus according to claim 4 further comprising a center support rail extending upward within said seat blade support into said mold region and interposed between said mechanical pusher elements and connected thereto such that said center support rail moves with said mechanical pusher elements. 
     
     
       6. The apparatus according to claim 4 wherein said alignment pin is located on at least one of said mechanical pusher elements. 
     
     
       7. The apparatus according to claim 1 wherein said seat blade support includes a plurality of cavity inserts displaced within said mold region and configured to slide within a plurality of cavity blocks during molding whereby a plurality of living hinges are provided along the length of said blade. 
     
     
       8. The apparatus according to claim 1 wherein said seat blade support includes a guard bar mold for forming a plurality of discontinuities along the length of said blade. 
     
     
       9. The apparatus according to claim 1 wherein said seat blade support includes a pair of opposing male mold members for forming a pair of opposing handle-locking cavities. 
     
     
       10. The apparatus according to claim 1 wherein said injection port is positioned within a movable mold element such that an initial movement of said mold element following the completion of the molding of said razor unit accomplishes a shearing of said razor unit from a thermoplastic waste member formed from excess thermoplastic material during the molding process.